Step-Forming Mold Structure for Uniform Capacitor Particle Density
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Solution Overview
Problem
Existing methods for manufacturing small-sized, high-capacitance electrolytic capacitors with porous sintered bodies face issues with uneven density distribution of valve metal particles, leading to reduced capacitance and increased leakage current due to excessive bonding and density differences near the anode wire surface.
Innovation Solution
A mold design with slidable upper and lower mold parts creates a step portion in the molding space, allowing metal particles to move from a larger initial space to a smaller space, reducing density differences and ensuring uniform particle distribution, which helps in embedding the anode wire firmly and preventing cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If valve metal particles are pressure-molded in a conventional mold without step portions, then the molding process is simple, but the density of particles near the anode wire surface becomes sparse, causing insufficient fixation of the anode wire
Solution Approach 1:
The mold is divided into multiple parts: a first mold part, a second mold part, and a third mold part with step portions. This segmentation allows different regions of the mold to perform different functions - the step portions in the third mold part create localized density variations that ensure uniform particle distribution and proper anode wire fixation, while the overall mold structure remains manageable
Solution Approach 2:
The step portions are pre-formed in the third mold part before the pressure molding process begins. This preliminary structuring of the mold ensures that when valve metal particles are introduced and pressure-molded, they naturally distribute with appropriate density variations, with higher density near the anode wire planting surface, eliminating the need for post-processing adjustments
2Strength
If valve metal particles are densely packed near the anode wire surface, then the anode wire is firmly fixed, but the particles become excessively bonded, reducing capacitance and increasing leakage current
Solution Approach 1:
The mold design creates local quality variations in particle density through step portions in the third mold part. The step portions are positioned to create localized regions of higher particle density near the anode wire planting surface, while other regions maintain lower density. This local differentiation ensures strong anode wire fixation at the planting surface without excessive bonding throughout the entire molded body, preserving capacitance and reducing leakage current
3Volume of moving object
If the mold defines a small molding space from the beginning, then the molded body size is reduced, but the metal particles cannot move freely, resulting in uneven density distribution
Solution Approach 1:
The third mold part introduces a vertical dimension with step portions that create height differences within the molding space. This dimensional variation allows metal particles to move freely in the horizontal plane while the step portions create localized regions of different volumes, enabling both free particle movement and controlled density distribution in the final compact molded body
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves a uniform density distribution of metal particles, enhancing the capacitance of the electrolytic capacitor and reducing leakage current by ensuring the anode wire is firmly fixed and minimizing density differences within the molded body.
Implementation Method 1
metal particles are pressed by advancing at least one of the pair of third mold parts in the initial space
Implementation Method 2
The lower mold part is configured to protrude toward the molding space with respect to the upper mold part so that a step portion due to a difference between a location of the upper mold part and a location of the lower mold part is formed
Data Source
AI summary
A mold includes a pair of first mold parts, a pair of second mold parts, and a pair of third mold parts that define six surfaces of a molded body substantially having a rectangular parallelepiped shape. At least one of the pair of third mold parts includes an upper mold part and a lower mold part. The upper mold part defines an upper space of a molding space, and the lower mold part defines a lower space of the molding space. The upper mold part and the lower mold part are individually slidable. The lower mold part protrudes toward the molding space with respect to the upper mold part so that a step portion is formed. The upper mold part is slidable in cooperation with the lower mold part in a state in which the step portion is formed or absent.